Personal support device with elongate inserts

ABSTRACT

A comfort device comprising a plurality of elongate inserts is disclosed herein. The comfort device can include one or more compartments configured to store the plurality of elongate inserts. The plurality of elongate inserts can have a length and a cross-section, where the cross-section has a cross-sectional area and a plurality of dimensions. The length of the inserts can be at least eight inches and at least eight times a greatest dimension of the cross-sectional area. The comfort device can include one or more openings and fastening mechanism corresponding to the one or more openings. The plurality of elongate inserts can generate tensional force in response to a force applied to the comfort device, thus providing improved elasticity for the comfort device.

FIELD OF THE DISCLOSURE

The present disclosure relates to personal support devices such aspillows and other types of cushions filled with a plurality of elongatedinserts of resilient material.

BACKGROUND

Personal support devices, such as pillows and cushions are used forproviding comfort for users when seated or lying down. Some such pillowsand cushions are filled with different types of inserts having differentmaterial properties and characteristics are used to provide usersdifferent levels of support and comfort. It is desirable to have aninsert that retains its volume and cushioning characteristic over time,while being breathable and washable. Various configurations, materials,and shapes have been proposed or implemented to provide adequate supportand comfort to the users.

SUMMARY OF THE INVENTIONS

The present disclosure includes, embodiments of systems, devices, andmethods for manufacturing cushions having a plurality of elongateinserts for providing physiological support for a user.

An aspect of at least one of the embodiments disclosed herein includesthe realization that using elongated ribbons of resilient material asfill for a personal cushion device can provide unexpected benefits. Forexample, in this context, it is significant to note that someconventional personal cushion devices, such as pillows, are often filledwith small, randomly-sized pieces of foam scrap. Such foam scrap, suchas those illustrated in FIG. 1, can have a size of about ½ to about 1½inches in diameter. Such pieces have random shapes and thus, althoughthe size of the pieces is characterized here as a diameter, such piecesare not necessarily spherical or even round. Rather, such pieces can bemany different random sizes and shapes.

Another aspect of at least one of the inventions disclosed hereinincludes the realization that such small, randomly shaped pieces ofresilient material are largely loaded only in compression or shearduring use and also suffer from durability issues, resulting inbreakdown and release of dust. For example, a conventional personalcushion device filled with such small, randomly sized pieces ofmaterial, is loaded in compression, when a user rests their head on thepillow. Under such a compression, the small, randomly sized pieces ofmaterial are largely loaded only in compression and shear. The resultingstresses on such small randomly sized pieces of material, usually opencell foam, results in undesirable breakdown and release of dust. This isdue to the greatly reduced, effective cross sectional areas that resultfrom resulting the grinding or shredding processes which concentrate theforces generated by loads onto small cross sectional areas therebyfurther concentrating the resulting stresses and increasing thelikelihood of failure.

An aspect of at least some of the inventions disclosed herein includesthe realization that filling a personal cushion device with pieces ofresilient material having a length larger than about 6 inches, resultsin an improved personal cushion device. For example, a personal cushiondevice can be filled with pieces of resilient material having a lengthlarger than about 6 inches, disposed in random, entangled orientations,can result in an increased likelihood that some of the pieces ofmaterial are loaded partially in tension during use. For example,elongated pieces of resilient material, when used as fill for a personalcushion device such as a pillow, and disposed in random orientations,will be entangled with each other. Such entanglement can result in somepieces having a first end entangled with other pieces disposed near aperiphery of the cushion and a second end entangled with other piecesdisposed closer to a center of the cushion. When the cushion isdepressed in the center, the second end of the elongated piece is pulleddownward with the central pieces and the first end remains substantiallystationary with the peripheral pieces. As such, the elongated piece canbe loaded in tension. This elongation can be similar to the loading ofsprings at the periphery of a trampoline, and thus can cause areactionary stretching/loading of the elongated ribbons in the personalcushion device. Such tensile loading of the elongated ribbons can resultin larger elastic elongations than possible under compression loadingresulting from small particulate-fill compositions used in knownpillows. As such, in some embodiments, a different cushioningperformance can be achieved with compared to cushions filled with smallrandomly sized pieces.

Another aspect of at least one of the inventions disclosed hereinincludes the realization that elongated ribbons, when used as fill forpersonal cushion devices, can provide better airflow through the cushionduring use. For example, an aspect of at least one of one of theinventions disclosed herein includes the realization that when elongatedresilient members, for example, having a length larger than about 6inches, are used as fill for personal cushion device, the elongatedmembers become entangled, similar to strands of spaghetti in a bowl ofspaghetti. The elongated members often lie in orientations extendingthrough rounded curves, thereby generating air gaps between adjacentelongated members. The air gaps formed in parts of the cushion that arenot compressed, define open air passages therebetween, supporting someairflow therethrough. Airflow through pillow is beneficial and desirableto some users who prefer “cooler” pillows or cushions.

Another aspect of at least one of the inventions disclosed hereinincludes the realization that elongated resilient members used as fillfor personal cushion devices can be more easily manufactured when theyhave shapes with outer surfaces that are alignable into continuousplanes when they are stacked. For example, some known pillows includeelongated fill members that have round cross sections. Elongated memberswith such a cross sectional shapes are typically punched or drilled fromfoam material. Alternatively, other roughly round cross sectional shapes(e.g., pentagonal, hexagonal, heptagonal, octagonal, etc.) could beformed by cutting with a cutting tool that is moved through virginmaterial with non-linear cuts. However, such a cutting technique isdifficult to perform, slower and results in additional waste. Incontrast, in accordance with at least one embodiment disclosed herein,an elongated resilient member can be formed with a cross section havingsides that are alignable into continuous planes when stacked. Such crosssections could be rectangular, square or triangular. Elongated memberswith such cross sectional shapes can be cut from blocks of virginmaterial with a plurality of straight, planar cuts. This results in asignificantly accelerated, less expensive, and less wastefulmanufacturing process.

Another aspect of at least one of the inventions disclosed hereinincludes the realization that resilient members used for as fill withinpersonal cushion devices can degrade over time, partly due to tearing.Tearing of resilient members used as fill within personal cushiondevices results when stress on such resilient members exceeds themaximum tensile or compressive strength of the member. Loading of a foammaterial, in particular an open cell foam material, results in allstresses being concentrated on the remaining cell walls within theinternal structure of the foam.

An aspect of at least one of the inventions disclosed herein includesthe realization that loads imparted onto resilient material pieceswithin a personal cushion device, including shear and tension forces,can be sufficiently large to tear such pieces of foam when thecross-sectional area of such elongated foam pieces are less than 1/16square inches. When such elongated resilient members are shaped withcross-sectional areas greater than approximately 1/16 square inches, ithas been found that they withstand the loads generated during use inpersonal cushion device for significantly longer life span withouttearing. As such, such personal cushion devices including elongated fillmaterial having a length of at least about 6 inches and across-sectional area of the least 1/16 square inches, have asignificantly longer life span without tearing, and generate less dust.

In some embodiments, the comfort device can comprise the following: (i)an outer cover comprising an upper sidewall and a lower sidewall; (ii) afirst internal compartment within the cover between the upper sidewalland the lower sidewall; (iii) an opening disposed in the outer cover,opening into the internal compartment of the outer cover; (iv) afastening assembly disposed at the opening comprising at least a firstfastening element, the fastening element being moveable between openedand closed positions; and (v) a plurality of elongated inserts disposedin the first internal compartment of the outer cover, the plurality ofelongated inserts comprising an open cell foam material, a first end, asecond end, an intermediate portion, and a length between the first endand the second end, the plurality of elongate inserts having a length ofat least 8 inches, the plurality of elongated inserts having across-section extending perpendicular to the length of the plurality ofelongated inserts, the cross-section defining a cross-sectional area ofat least one-sixteenth of an inch, the cross-section also comprising atleast a plurality of cross-sectional dimensions, and wherein the lengthis at least eight times a greatest one of the cross-sectionaldimensions. Additionally, an aspect of at least one of the inventionsdisclosed herein includes the realization that limiting thecross-sectional area of the elongated members can provide a less lumpyand smoother appearance for the associated comfort device. Thus, in someembodiments, the elongated members have a cross-sectional area of nomore than one square inch, ¾ of a square inch, ½ of a square inch, ⅜ ofa square inch, ¼ of a square inch, ⅛ of a square inch, 1/16 of a squareinch, or less. For example, a square cross-sectioned elongate memberhaving ¾″ long sides would have a 0.5635 sq. inch cross sectional area,which is about ½ of a square inch.

In some embodiments, the comfort device can further include one or moreof the following features in any combination: (a) wherein the pluralityof elongated inserts comprise a load deflection rating between 10 ILDand 40 ILD and a density between 0.5 pcf and 8.0 pcf; (b) wherein one ormore of the plurality of inserts have a uniform cross section along itslength; (c) wherein one or more of the plurality of insets has anon-uniform cross section along its length, for example, wherein a firstend has a first cross-section, a second end has a second cross-section,an intermediate portion has a third cross-section, wherein the firstcross-section and the second cross-section have the same cross-sectionalshape, and wherein the third cross-section has a differentcross-sectional shape than that of the first and the secondcross-section; (d) wherein a plurality of the elongate inserts havevarying lengths; (e) wherein the first end, the second end, and theintermediate portion of the plurality of elongate inserts have squarecross-sectional shapes; (f) wherein the outer cover of the comfortdevice comprises one or more compartments; (g) wherein the one or morecompartments have different volumes and shapes; (h) wherein the one ormore compartments house elongate inserts with different elasticproperties; and (i) wherein the fastening mechanism utilizes at leastone of the following mechanisms: zippers, hooks, ties, Velcro, clips,buttons, clasps, straps, and pins.

In some embodiments, the comfort device can comprise the following: (i)an outer cover comprising an upper sidewall and a lower sidewall; (ii) afirst internal compartment disposed within the cover between the uppersidewall and the lower sidewall; (iii) an opening disposed in the outercover, opening into the internal compartment of the outer cover; and(iv) a plurality of elongated inserts disposed in the first compartmentof the outer cover, the plurality of elongated inserts comprising anopen cell foam material, a first end, a second end, an intermediateportion, and a length between the first end and the second end, theplurality of elongated inserts having a cross section defining across-sectional area of at least one-sixteenth of an inch, thecross-section also comprising at least a plurality of cross-sectionaldimensions and wherein the length is at least eight times a greatest oneof the cross sectional dimensions.

In some embodiments, a method for batch manufacturing pillows filledwith a plurality of elongate inserts can be made from a block of foamcut in batches. For example, the method can comprise the following: (i)placing a block of foam material onto a cutting machine; (ii) cutting afirst batch of elongate inserts wherein the first batch has a firstvolume sufficient for a first pillow and collecting the first batch ofelongate inserts onto a first conveyor belt; (iii) moving the firstbatch of elongate inserts away from the block of foam material; (iv)cutting a second batch of elongate inserts from the block of foammaterial wherein the second batch has a second volume equivalent to atotal volume of a number of elongate inserts to needed for a secondpillow and collecting the second batch of elongate inserts onto thefirst conveyor belt; (v) wherein the first batch of elongate inserts isspaced from the second batch of elongate inserts.

Another aspect of the least one of the inventions disclosed hereininclude the realization that comfort devices such as cushions or pillowscan be manufactured in a more efficient manner, for example, by mixinglayers of different cushion materials into a larger block of cushionmaterial, prior to cutting the block of cushion material into its finalshape. For example, in some embodiments, a block of cushion material cancomprise a plurality of layers of different kinds of material. Thus,when further cuts are made to the block of material, the cut piecesinclude a mix of the different materials of the layers. Theconcentrations of the amounts of the first and second materials can bechanged by adjusting the number and magnitude of each plurality oflayers.

In some embodiments, the block of material can be cut in a manner so asto create at least partially mixed batches of cushion members, asubgroup of the cushion members being made from a first material and asecond subgroup of the cushion members being made from a seconddifferent material. In some embodiments, after the appropriate number ofbatches of cushion members are cut from such a multilayered,multi-material lock, the cushion members are then mixed so as to furthermix and randomize their distribution. The one or more batches of cushionmembers can then be inserted into a cushion shell.

In some embodiments, a block of mixed cushion materials can includegroups of layers of different materials. For example, a block of cushionmaterial comprising layers of two different materials can be arrangedwith all of the layers of one material being adjacent to one another andall of the layers of the second material being adjacent to each other,thereby dividing the block into two groups, independent and adjacent toeach other. The two groups of layers can be in direct contact, one grouplying on top of or adjacent to the other.

In some embodiments, different layers of a multi-material block can beintermingled with one another prior to cutting into the final shapes.For example, a block of cushion material can include a plurality oflayers of different materials with the layers arranged in an alternatingpattern. Thus, when the cushion members are cut from the multilayeredblock, some mixing of the cushion members has already been achieved byway of the alternating arrangement of the layers of the material. Suchwholly or partly premixed cushion members can be optionally mixed with adownstream mixing device prior to insertion into a cushion shell.

For purposes of summarizing the disclosure, certain aspects, advantages,and novel features have been described herein. Of course, it is to beunderstood that not necessarily all such aspects, advantages, orfeatures will be embodied in any particular embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates two different types of foam scraps used in prior artpillows.

FIG. 2 illustrates a prior art, single-block type of foam insert for apillow.

FIG. 3A is a schematic illustration of a pillow having a plurality ofpillow inserts.

FIG. 3B is a top, right and left side perspective view of the embodimentof the pillow of FIG. 3A.

FIG. 4A is a perspective view of a modification of the embodiment ofFIG. 3, in the form of a bedding pillow having a plurality of elongatepillow inserts.

FIG. 4B is a schematic view of a modification of the pillow of FIG. 4Ahaving a first arrangement of internal compartments.

FIG. 4C is a schematic view of a modification of the pillow of FIG. 4Ahaving a second arrangement of internal compartments.

FIG. 4D is a schematic view of another modification of the pillow ofFIG. 4A having a third arrangement of internal compartments.

FIG. 4E is a schematic view of yet another modification of the pillow ofFIG. 4A having a fourth arrangement of internal compartments.

FIG. 5 is a perspective view of three embodiments of elongate pillowinserts that can be used in the embodiments of personal cushion devicesdisclosed herein.

FIG. 6 is a schematic perspective view of an embodiment of an elongateinsert having a rectangular cross section.

FIG. 7 is a schematic perspective view of a modification of the elongateinsert of FIG. 6 having a different, triangular cross section.

FIG. 8 is another perspective view of an embodiment of a pillow having aplurality of elongate pillow inserts, showing additional detail ofinteraction between the elongate pillow inserts.

FIG. 9 is a schematic side elevational and partial cutaway view of anembodiment of a pillow, in a relaxed state and illustrating entangledgroups of elongated members, one group being near a center of thecushion and another group being closer to an edge of the cushion.

FIG. 10 is a schematic side elevational and partial cutaway view of thecushion of FIG. 9 with the group of elongated members near the center ofthe cushion being compressed and generating tension in an elongatedmember extending between the two groups.

FIG. 11 is a perspective view of a sheet material that can be used forforming different embodiments of elongate members that can be used forfilling other embodiments of cushions.

FIG. 12 is a perspective view of a block of virgin resilient materialwith optional cut lines for cutting the block into groups of elongatemembers for filling cushions.

FIG. 13A is a perspective view of the block of virgin resilient materialof FIG. 12, showing additional details of a sub-portion of the block ofvirgin resilient material.

FIG. 13B is a schematic end view of a group of elongated members withcircular cross-sections, stacked together with star shaped gapstherebetween.

FIG. 13C is a schematic end view of a group of elongated members withhexagonal cross-sections, stacked together.

FIG. 13D is a schematic end view of a group of elongated members withrectangular cross-sections, stacked together.

FIG. 13E is a schematic end view of a group of elongated members withtriangular cross-sections, stacked together.

FIG. 14 is a perspective view of a cutting machine having a conveyorbelt, illustrating an optional procedure for cutting a block of virginresilient material into groups of elongate members for filling acushion.

FIG. 15 is a perspective view of a collection of layers of two differentvirgin resilient materials with optional cut lines for cutting thecollection into groups of elongate members for filling cushions.

FIG. 16 is a perspective view of the collection illustrated in FIG. 15,with the layers being interleaved.

FIG. 17 is a perspective view of a collection of layers of fourdifferent virgin resilient materials with optional cut lines for cuttingthe collection into groups of elongate members for filling cushions.

FIG. 18 is a perspective view of the collection illustrated in FIG. 17,with an optional, further interleaved arrangement of the layers.

FIG. 19 is a perspective view of a cutting machine having a conveyorbelt, illustrating an optional procedure for cutting a block of virginresilient material into groups of elongate members and mixing the cutgroups prior to insertion into a cushion.

FIG. 20 is a flow diagram of an embodiment of a method of manufacturingpersonal cushion devices.

FIG. 21 is a flow diagram of another embodiment of a method ofmanufacturing personal cushion devices.

DETAILED DESCRIPTION

The embodiments disclosed herein are described in the context of pillowsused as bedding for supporting a user's head while lying down becausethey have particular utility in that context. However, the inventionsdisclosed herein can be used in other contexts as well, for example butwithout limitation, as cushions for seating such as on couches, chairs,animal bedding, bean bags, and other types of furniture.

Some of the currently available types of pillow inserts include, but notlimited to, down inserts, feather inserts, polyester fiberfill inserts,shredded foam inserts, buckwheat hull inserts, microbead inserts, andkapok pillow inserts. These types of inserts suffer from various typesof disadvantages. For example, Down and feather inserts requireconsistent fluffing, can be expensive, and can provide inconsistentlevel of support. Polyester fiberfill inserts can clump easily, can bepotentially hazardous, and do not breathe well. Buckwheat hull insertscan be heavy and too firm for some users. Microbead inserts can haveunpleasant chemical odor, can potentially release dangerous chemicalgases, and can have short lifespan because microbeads degenerate andflatten out with repeated use. Kapok inserts do not hold shape and caneasily develop lumps, thus requiring frequent readjustments.

FIG. 1 illustrates examples of the types of different shredded foaminserts 102 used in some prior art pillows. Shredded foam inserts 102can be manufactured using shredding machines, for example, by grindingor cutting foam pieces into randomly sized pieces. Some known pillowsare manufactured with scrap foam left over from other manufacturingprocesses. Such cuts can be irregular resulting in shredded foam inserts102 that are different shapes and sizes, which can be difficult andtime-consuming to manufacture.

In addition, shredded foam inserts 102 are prone to tearing. An aspectof at least one of the embodiments disclosed herein includes therealization that shredded foam inserts can have cross sectional areasthat are so small that the stresses generated during use can tear suchshredded foam inserts. Thus, shredded foam inserts 102 often do notmaintain their initial volume and shape after repeated use; they losethe ability to maintain air space/pockets as they tear and break downover time. When shredded foam pieces 102 lose the air space betweenthem, they tend to lose the ability to maintain their initial volumeand/or shape such that they cannot provide the same level of comfort.

FIG. 2 illustrates a different type of prior art pillow insert 104 thatis essentially a single block of foam with holes 108 punched or drilledthrough it. In some known pillows of this type, the insert 104 is madefrom one of the following materials including, but not limited to,polyurethane foam, memory foam, gel foam, latex rubber foam, convolutedphone, evlon foam, reflex foam, high density foam, high resiliencephone, Supreem™ foam, rebond foam, closed cell foam, or dry fast foam.Typically, the openings 108 typically have a circular cross-section, asshown in FIG. 2.

However, pillow inserts 104 made out of the block of foam, as shown inFIG. 2, can be quite heavy and expensive. Generating the openings 108 onthe pillow insert 104 can result in foam scraps in a form of short,small-cross-sectioned noodles that can be used as inserts for othertypes of pillows. However, such noodles tend to be much shorter and havesmaller cross-section than the pillow inserts disclosed herein. Becauseof the size and the method of manufacturing such inserts, a number ofthe single block type of pillow insert shown in FIG. 2 would need to bemanufactured to generate sufficient number of such elongate foam scraps(or noodles) to fill a single pillow of a similar size. Moreover, suchpillow inserts 104, while capable of providing adequate level of comfortfor users, can be significantly heavier than the shredded pillow inserts102.

FIGS. 3A and 3B are schematic diagrams illustrating an embodiment of acomfort device 100. The comfort device 100 can comprise a cover 160 anda plurality of elongated members 110. The comfort device 100 can be abedding pillow for supporting a user's head while lying down. However,with the appropriate sizing, the comfort device 100 can be configuredfor serving as a pillow or bed for a pet, the form of furniture commonlyknown as a “beanbag”, a sofa, a seat cushion, a back cushion, or otherapplications including, but not limited to, automotive, officefurniture, flotation devices, or sports equipment.

The cover 160 can be made out of various materials including, but notlimited to cotton, nylon, polyester, linen, silk or other materials. Insome embodiments, the cover 160 is made out of a breathable material. Insome embodiments, the cover 160 is made out of stretchable material. Thecover 160 can be substantially rectangular or circular. In otherembodiments, the cover 160 can be spherical. In the context of thecomfort device being in the configuration of a “bean bag” typefurniture, the cover can be substantially spherical or partiallyspherical and partially seat-shaped. In some embodiments, the cover 160can be configured to assume and maintain different types of shapes.

As shown in FIGS. 3A and 3B, the comfort device 100 is in theconfiguration of a bedding pillow for supporting a user's head whilelying down. The cover 160 is substantially rectangular and/orsack-shaped, such as the shape of a conventional pillow used as forbedding. The cover 160 can include a first side 170, a second side 172,a third side 174, a fourth side 176, a first surface 180, and a secondsurface 182. The first side 170 can be located distal or opposite fromthe third side 174 and the second side 172 can be located distal oropposite from the fourth side 176. The first side 170 and the third side174 can be facing one another while the second side 172 and the fourthside 176 can be facing one another. The first 164 a, the second side172, the third side 174, the fourth side 164 c can be configured definethe boundaries of the first surface 180 and the second surface 182. Thefirst surface and the second surface 180, 182 can be arcuate. In someembodiments, the first surface and the second surface 180, 182 aresubstantially flat. The schematically represented configuration of sidesand surfaces is just one example of cover of a pillow that can be usedto form a comfort device 100. Other configurations can also be used.

In some embodiments, the first surface 180 is a top surface and thesecond surface 182 is a bottom surface of the comfort device 100. Duringuse, a user might flip the comfort deice 100 over to switch theorientations of the sides 180, 182. As such, the comfort device of FIGS.3A and 3B is configured for use in any orientation.

The first surface 180 and the second surface 182 can extend between thefirst side 170 and the third side 174 of the cover 160 and the firstsurface 180 and the second surface 182 extend between the second side172 and the fourth side 176 of the cover 160. The first surface 180 andthe second surface 182 can be substantially rectangular, each havingfour sides that are connected to the first, second, third, and fourthsides 170, 172, 174, 176 of the cover 160. The first surface 180 and thesecond surface 182 can be configured such that their inner surfaces faceeach other and their outer surfaces face away from each other. In someembodiments, the first surface 180 is an upper sidewall while the secondsurface 182 is a lower sidewall.

In other embodiments, the cover 160 includes more than four sides. Insome embodiments, the cover 160 includes less than four sides. In otherembodiments, the cover 160 is substantially a rectangular cuboid withsix faces. The cover 160 can be circular or elliptical. In someembodiments, the cover 160 can be substantially spherical.

The cover 160 can include one or more internal compartments 168 definedwithin the sides 170, 172, 174, 176, and the top and bottom 180, 182.The embodiment of the comfort device 100 illustrated in FIGS. 3A and 3Bincludes a single internal compartment. As such, the first side 170, thesecond side 172, the third side 174, the fourth side 176, the firstsurface 180, and the second surface 182 of the cover 160 can defineboundaries for the compartment 168. In some embodiments, variouscombinations of the first side 170, the second side 172, the third side174, the fourth side 176, the first surface 180, and the second surface182 of the cover 160 can define boundaries for the compartment 168.

In some embodiments, the compartment 168 of the cover 160 can contain aplurality of elongated members 110. The elongated members 110 can haveone or more different cross-sectional shapes and cross-sectional areas.In some embodiments, the length of the inserts can vary. In otherembodiments, all, a majority or a substantial number of the elongatedmembers 110 have the same length. The elongated members 110 can beplaced into the compartment 168 of the cover 160 via an opening 162. Theopening 162 can be associated with any of the sides or the surfaces ofthe cover 160.

FIG. 4A illustrates another embodiment of the comfort device 100 of FIG.3, identified generally by the reference numeral 100 a. Parts,components, and features of the comfort device 100 a are identifiedusing the same reference numerals as the corresponding parts,components, and features of the comfort device 100, except that a letter“a” has been added thereto. The illustrated embodiment of the comfortdevice 100 a includes a cover 160 a and elongated members 110 a.

As shown in the FIG. 4A, the cover 160 a can comprise an opening 162 aand a fastening mechanism associated with the opening 162 a. The covercan include a first side 170 a, a second side 172 a, a third side 174 a,and a fourth side 176 a. The first side 170 a, the second side 172 a,the third side 174 a, and the fourth side 176 a can define boundariesfor a first surface 180 a and a second surface 182 b (not shown). Asdiscussed above, the first and the second surfaces 180 a and 182 a canbe positioned such that inner surfaces of the first and the secondsurfaces 180 a and 182 a face each other. The cover 160 a can be madeout of materials as described above. The cover 160 a can be in differentshapes including, but not limited to, cylindrical, substantiallyrectangular, circular, or sack-shaped such as that commonly used forbedding pillows, or any other shape. The cover 160 a can havecross-sections in different shapes. For example, the cross-section ofthe cover 160 a can be elliptical or substantially rectangular. Thecover 160 a can comprise different types of surface indentations toprovide additional comfort and/or support for the users.

For example, as shown in FIG. 4A, the cover 160 a has one or moredimples and/or protrusions to provide additional comfort and/or support.The protrusions, shown in FIG. 4A, can include different elements toprovide cushioning/energy absorption. In some embodiments, such divotsand/or protrusions are disposed on an outer surface of the cover 160 a.In other embodiments, such divots and/or protrusions are disposed on aninner surface of the cover 160 a.

In some embodiments, the opening 162 a can be associated with either thefirst side 170 a or the third side 174 a of the cover 160 a. The opening162 a can be dimensioned such that its length is less than or equal tothe lengths of either the first side 170 a or the second side 172 a ofthe cover 160 a, as is typical in the generally rectangular shape of abedding pillow.

The fastening mechanism of the cover 160 a is configured to interactwith the opening 162 a of the cover 160 a to allow users ormanufacturers to open or close the opening 162 a. The fasteningmechanism can have two positions corresponding to the state of theopening 162 a. For example, the fastening mechanism can have an openposition in which the opening 162 a is open. When the fasteningmechanism is in a closed position, the opening 162 a is closed. In someembodiments, the fastening mechanism has more than two positions.

The fastening mechanism can be associated with either the first side 170a or the third side 174 a of the cover 160 a. The fastening mechanismcan incorporate various types of mechanisms including, but not limitedto, zippers, hooks, ties, Velcro, clips, buttons, clasps, straps, orpins. In some embodiments, the fastening mechanism is not associatedwith either the first side 170 a or the second side 172 a of the cover160 a. In some embodiments, the fastening mechanism 180 is associatedwith the opening 162 of the cover 160.

In some embodiments, the cover 160 a can include one or morecompartments 168 a that are dimensioned to contain a plurality ofelongated members 110 a. In some embodiments, each of the compartments168 a is associated with at least one opening to allow a user to placethe desired number of elongated members 110 a into each of thecompartments 168 a. Optionally, having discrete compartments 168 awithin the comfort device 100 a can allow a user to insert elongatedmembers 110 a with different characteristics (e.g., size, density,and/or length) within different compartments 168 a. For example, theelongated members 110 a with higher density may be placed within acompartment 168 a located closer to the ends 170, 174 and the cover 160a while the elongated members 110 a with lower density may be placedwithin a compartment 168 a located farther from the ends 170, 174.

FIGS. 4B-4E illustrate other embodiments of the cover 160 of the comfortdevice 100 of FIGS. 3A and 3B, identified generally by the referencenumeral 160 b, 160 c, 160 d, and 160 e. Parts, components, and featuresof the cover 160 b, 160 c, 160 d, and 160 e are identified using thesame reference numerals as the corresponding parts, components, andfeatures of the comfort device 100, except that letters “b”, “c”, “d”,and “e” have been added thereto.

As shown in FIG. 4B, in some embodiments, the cover 160 b has twocompartments 168 b separated by a divider 190. As described above, thecover 160 b can comprise a first side 170 b, a second side 172 b, athird side 174 b, and a fourth side 176 b. The first compartment can beassociated with a first opening and the second compartment can beassociated with a second opening. In some embodiments, the compartments168 b are equal in size and volume. In other embodiments, the firstcompartment is larger in size and volume than the second compartment.The first compartment and the second compartment can be arranged suchthat they are adjacent to one another. In some embodiments, thecompartments 168 b can be arranged such that the first compartment islocated on top of the second compartment. In some embodiments, the cover160 b has two or more compartments 168 b.

FIG. 4C illustrates an embodiment of the cover 160 c including threecompartments 168 c separated by dividers 190 c. As described above, thecover 160 c can comprise a first side 170 c, a second side 172 c, athird side 174 c, and a fourth side 176 c. The first compartment 168 ccan be associated with a first opening 162 c while a second compartment168 c can be associated with a second opening 162 c. In someembodiments, a third compartment can have an opening 162 c associatedwith a side 176 c of the cover 160 c, or with an internal divider 190 cso that the third compartment 168 c opens into an adjacent compartment168 c and thus can be emptied and filled through the adjacentcompartment 168 c. Optionally, in some embodiments, the compartments 168c are equal in size and volume. The compartments 168 c can havedifferent sizes and volumes. The compartments 168 c can be arranged suchthat they are adjacent to one another, as shown in FIG. 4C. However, thecompartments 168 cs can also be arranged such that the first compartmentis adjacent to a top surface of the cover 160 c, the second compartmentadjacent to a bottom surface of the cover 160 c, and the thirdcompartment located between the first and the second compartment. Insome embodiments, the compartments 168 c are stacked on top of eachother.

FIG. 4D illustrates the cover 160 d including four compartments 168 dseparated by dividers 190 d. As discussed above, the cover 160 d cancomprise a first side 170 d, a second side 172 d, a third side 174 d,and a fourth side 176 d. A first compartment and a second compartmentcan be associated with a first opening 162 d while a third and a fourthcompartment can be associated with a second opening 162 d. In someembodiments, the compartments 168 d are equal in size and volume.Optionally, the compartments 168 d can have different sizes and volumes.In some embodiments, the compartments 168 d are arranged such that eachof the four compartments 168 d are generally located at four quadrantsof the cover 160 d. However, the compartments 168 d can also be arrangedwith the first compartment adjacent to a top surface of the cover 160 d,the second compartment adjacent to a bottom surface of the cover 160 d,and the third and the fourth compartments 168 d located between thefirst and the second compartment. In some embodiments, the compartments168 d are stacked on top of each other as shown in FIG. 4E.

FIG. 5 illustrates a perspective view of an embodiment of the elongatedmember 110 a. The elongated member 110 a can include a first end 120 a,a second end 130 a, and an intermediate portion 140 a. The elongatedmembers 110 a can have a cross-section of any shape, including butwithout limitation, square, round, triangular rectangular, polygonal, orother shapes.

Optionally, in some embodiments, the elongated members 110 a have across sectional shape defining sides that can be alignable intocontinuous planes. For example, triangular, rectangular, parallelogram,diamond and square cross sections define sides that can be aligned intocontinuous planes when such inserts are stacked with each other. Othercross sections do not provide this structural relationship. For example,if elongated members having round, oval, pentagonal or hexagonal crosssections are stacked together, the sides of adjacent members cannot bealigned along continuous planes. Rather, the sides are spaced from eachother with non-uniform gaps or follow zig-zagging paths. The non-planaralignment of the sides of such elongated members when stacked is aresult of those elongated members being manufactured in more complex andlimited processes.

By contrast, where the elongated members 110 include sides that arealignable so as to extend continuously along planes, such elongatedmembers can benefit from the optional advantage of manufacturing bymaking straight cuts through blocks of virgin material, such as foam.Exemplary manufacturing processes are described below with reference toFIGS. 14-17.

With regard to overall shape of the elongated members 110 a, the firstend 120 a, the second end 130 a, and the intermediate portion 140 a ofthe elongated members 110 a can have the same cross-section. In someembodiments, the first end 120 a, the second end 130 a, and theintermediate portion 140 a have different cross-sections. In someembodiments, the elongated members 110 a are made out of virginresilient materials, such as, but without limitation, open cell foamsthat can provide more breathability, lower density, and less totalweight than closed cell foams.

FIGS. 6 and 7 are schematic diagrams of variations of the elongatedmembers 110, detailing the cross-sectional uniformity and/or variationsalong their length. The variations of FIGS. 6 and 7 are identified withthe reference numerals 110 b and 110 c. Parts, components, and featuresof the cover 110 b and 110 c are identified using the same referencenumerals as the corresponding parts, components, and features of theelongated members 110 a, except that letters “b” and “c” have been addedthereto.

With reference to FIG. 6, the elongated member 110 b can include a firstend 120 b, a second end 130 b, and an intermediate portion 140 b. Thefirst end 120 b can comprise a first cross-section 122 b with a width124 b and depth 126 b and the second end 130 b can comprise a secondcross-section 132 b, with a width 134 b and depth 136 b. Theintermediate portion 140 b can comprise a third cross-section 142 b witha width 144 b and depth 146 b. The depths and widths 124 b, 134 b, 144 band depths 126 b, 1365 b, 146 b can be the same or can vary from eachother. In some embodiments, the widths 124 b, 134 b, 144 b and depths126 b, 1365 b, 146 b can be manufactured with straight edged cuttingtools, yet vary due to normal cutting tool operation. In otherembodiments, the widths 124 b, 134 b, 144 b and depths 126 b, 1365 b,146 b can vary by design.

The first end 120 b, the second end 130 b, and the intermediate portion140 b of the elongated member 110 b can have different cross-sectionalshapes including, but not limited to, square (FIG. 6), circular,elliptical, triangular (FIG. 7), or hexagonal. In some embodiments, thefirst cross-section 122 b, the second cross-section 132 b, and the thirdcross-section 142 b have different cross-sectional shapes. In otherembodiments, the first cross-section 122 b, the second cross-section 132b, and the third cross-section 142 b have the same cross-sectionalshape. In other embodiments, the first cross-section 122 b and thesecond cross-section 132 b have different cross-sectional shapes. Insome embodiments, the first cross-section 122 b and the secondcross-section 132 b have the same shape while the third cross-section142 b has a different shape from that of the first and the secondcross-sections 122 b, 132 b.

The elongated members 110 b can have a length 150 b defined between thefirst end 120 b and the second end 130 b. Varying the lengths 150 b canresult in different elastic properties and compressive responses of theelongated members 110 b. For example, the elongated members 110 b havinga length of 4-6 inches can be less flexible and less able to generateand maintain larger air gaps than the elongated members 110 b having alength larger than about 6 inches or greater. In some embodiments, thecomfort device 100 comprises elongated members 110 b having differentlengths 150 b.

In some embodiments, the length 150 of the elongated member 110 b isbetween about 6 inches and 14 inches, between about 10 inches and 14inches, between about 8 inches and 12 inches, between about 5 inches and10 inches, or about 7 inches, 8 inches, 9 inches, 10 inches, 11 inches,12 inches, 13 inches, 14 inches, or ranges including two of theaforementioned values. In some embodiments, the length 150 of theelongated members 110 can be at least 6 inches. In other embodiments,the length 150 of the elongated members 110 can be at least 8 inches.

The length 150 b of the elongated members 110 b can be at least 15 timesany of the widths 124 b, 134 b, 144 b or depths 126 b, 1365 b, 146 b ofthe elongated members 110 b. In some embodiments, the length 150 b ofthe elongated members 110 b is at least 20 times the width or depth ofthe elongated members 110 b. Some embodiments of the elongated members110 b can include circular cross-sections. In such cases, the length 150b of the elongated members 110 b can be at least 20 times the diameterof the elongated members 110 b.

The first, second, and third cross-sections 122 b, 132 b, 142 b of theelongated members 110 b are associated with cross-sectional areas 128 b,138 b, 148 b, which can be between about 0.0625 in.² and 0.25 in.²,between about 0.09 in.² and 0.5625 in.², between about 0.25 in.² and0.445 in.², between about 0.4 in.² and 1 in.², or about 0.0625 in.²,0.09 in.², 0.25 in.², 0.4 in.², 0.445 in.², 0.5625 in.², 1 in.², orranges including any two of the aforementioned values. In someembodiments, the elongated members 110 b have cross-sectional area of atleast one-sixteenth of a square inch. The elongated members 110 b of thecomfort device 100 can undergo various types and levels of tensile,compressive, shearing stress and/or bending moment during regular use ofthe comfort device 100. The cross-sectional areas 128 b, 138 b, 148 band the material properties of the elongated members 110 b can affectthe ability of the elongated members 110 b to better withstand thetensile, compressive, shearing stresses, and bending moments resultingfrom the regular uses of the comfort device 100.

With reference to FIGS. 8-10, the elongated members 110 b of the comfortdevice 100 can undergo various types and levels of tensile stress,shearing stress and/or bending moment from regular uses of the comfortdevice 100. The length 150 b and the material properties of theelongated members 110 b can affect the ability of the elongated members110 b to withstand shearing stress, bending moments, and/or torqueresulting from the regular uses of the comfort device 100. Furthermore,the length 150 b of the elongated members 110 b can also affect theelastic properties and/or compressive responses of a pillow filled withthe elongated members 110 b. For example, greater lengths 150 b of theelongated members 110 b can result in better compressive responses ofthe comfort device 100 a.

FIG. 8 illustrates the embodiment of the comfort device 100 a of FIG.4A, showing additional details of the elongated members 110 a. Theelongated members 110 a, as shown in FIG. 8, can interact with oneanother and the cover 160 a to provide beneficial or desirable effects.Some such effects are associated with longer elongated members.

In some embodiments, the elongated members 110 b have a density, whichcan be between about 0.5 pound per cubic feet (pcf) and 5 pcf, betweenabout 1.5 pcf and 3.5 pcf, between about 2.0 pcf and 3.0 pcf, or about0.5 pcf, 1.0 pcf, 1.5 pcf, 2.0 pcf, 2.5 pcf, 3.0 pcf, 3.5 pcf, 4.0 pcf,4.5 pcf, 5.0 pcf, or ranges including any two of the aforementionedvalues. The elongated members 110 b of the comfort device 100 canprovide varying levels of comfort and support for the users depending onthe density of the elongated members 110 b. The elongated members 110 bcan have different compressive responses and/or elastic propertiesdepending on the density of the elongated members 110 b.

In some embodiments, the volumetric ratio between total volume of theelongated members 110 b in an uncompressed state and the total volume ofthe comfort device 100 is between about 0.5 and 0.95, between about 0.6and 0.8, between about 0.7 and 0.75, or about 0.5, 0.55, 0.6, 0.65, 0.7,0.75, 0.8, 0.85, 0.9, 0.95, or ranges including any two of theaforementioned values.

As described above, when the elongated members 110 b are inserted intothe cover 160, the elongated members 110 b can be disposed in randomorientations, bent and/or looped around themselves and/or one another,resembling entangled strands of spaghetti. Thus, normally, when theelongated members 110 b are inserted into a cover 160, they are notarranged into a tight, compact configuration extending parallel to oneanother. Rather, the random, entangled orientation results in asignificant amount of gaps and air spaces between the elongated members110 b. Such air gaps and spaces improve breathability of the comfortdevice 100. Additionally, an aspect of at least one of the inventionsdisclosed herein includes the realization that longer members 110improve the formation and maintenance of such gaps and spaces. Forexample, shorter members such as about 6 inches and shorter create alesser amounts of gaps and spaces. However, members of about 6 inches inlength and longer, can form more arcuate bends and fuller loops, therebycreating significantly more gaps and spaces inside the cover 160 of thecomfort device 100.

Varying the volumetric ratio can also result in different levels ofcomfort and support for the users. For example, smaller volumetricratios can provide less support for the users. On the other hand,greater volumetric ratios can provide more support for the users. Insome embodiments, the volumetric ratio between 0.75 and 0.9 can providethe optimal level of support and comfort for particular users dependingon their personal references.

As shown in FIGS. 9 and 10, the ends of an elongated member 110 b can beentangled with other elongated members 110 b inside a comfort device 100b. For purposes of describing one possible mode of tensile loading of anelongated member 110 b, FIGS. F and 10 show in isolation, the ends ofone elongated member 110 b can be entangled with other inserts in twodifferent areas of the comfort device 100 b, one end entangled in anarea toward the center C of the comfort device 100 b and the other endentangled in an area closer to an edge E of the comfort device 100 b.

Applying this hypothetical orientation, during use, when a load isapplied to an upper surface of the central area C of the cushion, theelongated members and the portions thereof located in the central areaare compressed downwardly, in the direction of the arrow. As such, andone end of the isolated elongated member 110 b is pulled downwardly asthe central area C is depressed. However, the second end being entangledwith the uncompressed portion of the comfort device 100 near the edge E,remains relatively more stationary. As such the elongated member 110 bcan be loaded in tension because one end is pulled away from the other.This tensile loading of the elongated member 110 b can create adifferent response of the comfort device to loading during use, like atrampoline which is a different loading dynamic than foam loaded solelyin compression. Significantly, such tensile loading is different fromthe loading mechanisms normally subjected to small, randomly sized fillmaterial, such as that illustrated in FIGS. 1 and 2, e.g., compressiononly.

As noted above, the comfort device 100 with pieces of resilient materialhaving a length of more than about 6 inches can result in an improvedcomfort device 100, and more significantly with elongated members 110that are 8 inches or longer. For example, the comfort device 100 can befilled with elongate pieces of resilient material having a length largerthan roughly 6 inches, disposed in random orientations, in which theelongate pieces of resilient material (e.g., elongated member 110 a) canbe entangled with each other. In such configuration, some elongatepieces of resilient material can have first ends entangled with elongatepieces located at a periphery of the comfort device 100 and second endsentangled with elongate pieces located near the center of the comfortdevice 100. This is just one illustrative example of an orientation thatcan result in the tensile loading of an elongated member 110. However,as noted above, the elongated members 110 would be randomly orientedwithin the comfort device 100. The collective loading of such longerelongated members 110 results in more tensile loading of the elongatedmembers 110 compared to the loading of shorter elongated members 110.Thus, generally speaking, longer elongated members 110 can be loadedboth in compression and more in tension while shorter elongated members110 tend to be loaded more in compression only and or less in tension.

Thus, when a load is applied near the center portion of the comfortdevice 100, the elongate pieces located near the center are pusheddownward, causing the second ends of the elongated pieces to be pulleddownward. As such, tension can be created between the relativelystationary first ends and the second ends which are pushed downward,causing the elongate pieces to stretch. This tension and stretch can besimilar to the loading of springs at the periphery of a trampoline, andthus can cause a reactionary stretching/loading of the elongated piecesin the personal cushion device 100. Such tensile loading of theelongated pieces can result in larger elastic elongations than possibleunder compression loading resulting from small particulate fillcompositions. As such, in some embodiments, a different and desirablecushioning performance can be achieved compared to cushions filled withsmaller, shorter and/or more randomly sized pieces.

More specifically, when a force is applied to the elongated member 110 bin a first direction, a first end of the elongated member 110 b can bemoved in the first direction while a second end of the elongated members110 b can remain substantially stationary. The second end, in someembodiments, is tangled within a complex macrostructure of the inserts100 b and thus does not move, or moves vary slightly, when the force isapplied. In such configuration, the first end of the elongated member110 b can be stretched away from the fixed end, creating a tensionbetween the first end and the second end of the elongated member 110 b.This tension can create a resilient, trampoline-like effect.

The magnitude of the tension force can be proportional and/or associatedto one or more properties including, but not limited to, material of theelongated member 110 b, lengths of the elongated members 110 b,cross-sectional areas of the elongated members 110 b, the magnitude ofthe force, volumetric ratio between the total volume of the elongatedmembers 110 b and the total volume of the comfort device 100 b, theweight ratio between the total weight of the elongated members 110 b andthe total weight of the comfort device 100 b, the average amount of airspace and/or volume between the elongated members 110 b, the length ofthe free end, the length of the fixed end, or the amount of forcegenerated via friction between the elongated members 110 b.

It can be advantageous for the elongated members 110 to have smaller orlimited cross-sectional areas as such a configuration can provides amore uniform “feel” to the user of the comfort device. For example,smaller cross sectional shapes of the elongate members can result in asmoother, less lumpy feel or appearance of the comfort device 100.However, the tensile loading of longer elongated members 110 b inaddition to the compression loading, results in higher stresses on theelongated members 110 b. Thus, in some embodiments, limiting the crosssectional area to a range can provide optional benefits of balancing theimproved durability resulting from larger cross-sections with thesmoother appearances and feeling that can result from smallercross-sections. For example, the minimum cross-sectional area of theelongate foam elongated members 110 can be a predetermined number, forexample, of about 1/16^(th) of an inch or greater. Where the elongatedmembers 110 b are made from open cell foam, a minimum cross-sectionalarea of about 1/16 of an inch for elongated members 110 b having alength of more than about six inches has resulted in improved reductionin tearing and thus better durability. A significant additionalimprovement results from using elongated members 110 having a minimumcross-sectional area of about ¼ of 1 inch, and significantly where thelength of the elongated members 110 is about eight inches or more. Thelonger elongated members 110 are loaded in tension to even a greaterextent, and thus, the larger minimum cross-sectional area associatedwith longer elongated members 100 can provide significantly improvedresistance to tearing and greater durability.

In some embodiments, the minimum cross-sectional area is calculatedusing at least one of the following variables including, but not limitedto, length of the elongated members 110, material of the elongatedmembers 110, the cell-structure of the elongated members 110, thelargest dimension of cross-sections of the elongated members 110, andthe volumetric ratio between the elongated members 110 of the comfortdevice 100.

As noted above, having a minimum cross-sectional area of at least 1/16,⅛ or ¼ of an inch can improve the performance and durability of theelongated members 110. Additionally, limiting the cross-sectional areaof the elongated members 110 can provide a less lumpy and smootherappearance for the associated comfort device 100. Thus, in someembodiments, the elongated members have a cross-sectional area of nomore than one square inch, ¾ of an inch, ½ an inch, ⅜ of an inch, or ¼of an inch.

As noted above, in some embodiments, the elongated members 110 b can bemade from open cell foams as opposed to closed cell foams. Open cellfoams are filled with air and have tiny cells that are not completelyclosed. On the other hand, closed cell foams have cells that arecompletely closed. The structural difference between open cell foams andclosed cell foams lead to different level of durability and elasticity.While open foam cells are more elastic than closed cell foams, they areless durable. Thus, it can be beneficial to have, for some embodiments,a minimum cross-sectional area—as listed above—for elongate foamelongated members 110 b made from open cell foams in order to reducestructural degradation and/or dusting from repeated uses.

FIG. 11 is a schematic illustration of a material that can be used toform a variation of elongated inserts for the comfort device 100. Asshown in FIG. 11, the insert material 210 can include outer surfaces 220and an inner portion 230. The outer surfaces 220 can comprise one ormore openings 222 that allow air to flow through the outer surfaces 220and the inner portion 230. In some embodiments, the openings 222 are insame size. In other embodiments, the openings 222 vary in size.

The inner portion 230, e.g., the area between the outer surfaces 230 caninclude a webbing 232 that can comprise a complex structure made out ofone or more fibers 234. The fibers 234 can be made out of variousdurable, yet flexible materials. In some embodiments, the fibers 234 cancomprise a first end and a second end, the first end attached to a firstouter surface 220, the second end attached to a second outer surface220. In some embodiments, the fibers 234 generally define a verticalaxis between the outer surfaces 220. In some embodiments, the fibers 234are substantially vertical with respect to the outer surfaces 220. Insome embodiments, the fibers 234 are disposed at an angle such that oneend of the fibers 234 are at an obtuse angle with respect to the outersurface 230 and another end of the fibers 234 are at an acute angle withrespect to the outer surface 230.

FIGS. 12-14 illustrate steps of embodiments of methods of manufacturingelongated members 110 from a block 300 of virgin foam. As used herein,the term “virgin” refers to a bulk form of foam that has been formed ina large piece, and which has not been previously cut apart into smallpieces and put back together, for example, with adhesive.

The block 300 can be made out of various materials including, but notlimited to, polyurethane foam, memory foam, gel foam, latex rubber foam,convoluted phone, evlon foam, reflex foam, high density foam, highresilience phone, Supreem™ foam, rebond foam, closed cell foam, or dryfast foam. The block 300 can be in different shapes. In someembodiments, as shown in FIG. 12, the block 300 can be a cubic or alarge roll having side quadrilateral faces. Some forms of bulk foamblocks can be as large as a truck or a school bus. In any of theseforms, the block 300 can be considered “virgin” material or foam, asused herein.

For purposes of this description, the block 300 can be considered ashaving length, denoted as A in FIG. 12, which can be at least about 10inches with some block being as long as 200 inches or as much as 100feet (commercially available in a compressed roll). In some embodiments,the length of the block 300 is a whole-number multiple of a dimension ofthe elongated members 110 such that there will be no scrap segments ofthe block 300 after all cuts are made. For example, the length A of theblock 300 may be 20 times as long as the length 150 b, width 124 b ordepth 126 b (FIG. 6) of the elongated members 110 b to be manufactured.

The block 300 can also be considered as having a width, denoted as B inFIG. 12, which can be between about 10 inches and 200 inches. In someembodiments, the width B of the block 300 can be a multiple of adimension of the elongated members 110 such that there will be no scrapsegments of the block 300 after cuts 310 are made. For example, thewidth B of the block 300 may be 20 times as long as the length 150 b,width 124 b or depth 126 b (FIG. 6) of the elongated members 110.

The block 300 can also be considered as having a height, denoted as C inFIG. 12, which can be between up to about 200 inches, or other sizes. Insome embodiments, the height of the block 300 is a multiple of adimension of the elongated members 110 such that there will be no scrapsegments of the block 300 after cuts 310 are made. For example, theheight C of the block 300 may be 20 times as long as the length 150 b,width 124 b or depth 126 b (FIG. 6) of the elongated members 110.

In some embodiments, an initial step can include cutting a bulk block300 down to a desired width B, height C and/or length A so that thosedimensions are whole-number-multiples of the length 150 b, width 124 bor depth 126 b (FIG. 6) of the elongated members 110 that are plannedfor manufacturing from the block 300. In some circumstances, due topractical limitations of the device used to cut the elongated members110 from the block 300, there may be pieces of the block 300 left overwhich cannot be cut using the same technique or device.

For example, described in greater detail below is a foam cutting machinehaving both vertical and horizontal saw blades and two conveyor belts,all of which are digitally controlled for precise movements. However,some such machines cannot practically or accurately cut small pieces ofmaterial.

FIG. 12 is a schematic perspective view of a block of foam 300 with aninitial layout of some of the cuts that can be made to the block 300 forforming a plurality of elongated members 110. Cuts 310 can be made usingvarious types of mechanisms including, but not limited to, laser, cablelaw, circular saw, or pressurized water. In some embodiments, cuts 310are made for each individual elongated member 110. In other embodiments,cuts 310 are made in a way such that more than one elongated members 110can be formed in batches.

In some embodiments, cuts 310 can be vertical or horizontal. Forexample, horizontal cuts 310 h are made to have a cutting planesubstantially parallel to the x-y axis. In addition, vertical cuts 310 vcan be made to have a cutting plane substantially parallel to the x-zaxis. Furthermore, longitudinal cuts 310 l can be made to have a cuttingplane substantially parallel to the y-z axis.

In some embodiments, horizontal cuts 310 h can be made to cut the block300 into horizontal sheets 301, 302, 303, 304 having flat surfacesparallel to the x-y axis. Likewise, longitudinal cuts 310 l can be usedto split the sheets into two or more parallel sheets. Moreover, verticalcuts 310 v can be used to cut a plurality of fully formed elongatedmembers 110 from the block 300, for example, in one pass.

In some embodiments, the cuts 310 are linear. In other embodiments, thecuts 310 are not linear. For example, the cuts 310 may comprise one ormore arcuate, stepped, and/or discontinuous cutting planes. Cuts 310 canbe made to the block 300 to manufacture elongated members 110 withdifferent cross-sections. For example, as described above, cuts 310 withcutting planes parallel to the x-y axis, x-z axis, and the y-z axis canmanufacture elongated members 110 that are substantially cuboid with sixquadrilateral faces. On the other hand, cuts 310 made while maintaininga fixed distance away from an axis parallel to either of the x-axis,y-axis, or the z-axis can manufacture elongated members 110 that arecylindrical in shape.

FIG. 13A illustrates the layout of a series of horizontal, longitudinaland vertical cut lines showing with the cut 310 h, 310 l, and 310 vwould be made to cut fully formed elongated members 110 b from the block300 without any leftover pieces. Although not illustrated, in use, theremay be scrap left over after the final cut, for example, when the lastremaining piece of the block 300 falls over or is otherwise too small tobe cut by the machine 400. Such a sequence of cutting can providesignificant other optional benefits. For example, an aspect of at leastone of the inventions disclosed herein includes the realization thatelongate members with sides that are alignable into continuous planescan be cut with more efficiency than elongate members that have morecomplex shapes.

For example, FIGS. 13B and 13C are schematic end views of stackedelongate members 110 o (having a round cross section) and 110 p (havinga pentagonal cross section). In both figures, the elongated members 110o, 110 p are stacked together as tightly as possible. However, the sidesof the elongated members 110 o, 110 p are not alignable into continuousplanes. Rather, the sides of the members 110 o only make contacttangentially, leaving star shaped gaps G therebetween. The pentagonalmembers 110 p, on the other hand, touch along flat sides, but the sidesare not alignable into continuous planes. Rather, the sides of themembers 100 p fall along a zig-zag path Z.

Cutting either of these types of members 110 o, 110 p is more difficultas such would require drilling, punching, or chopping. Such techniquesbecome more difficult with longer elongated members and especially withsmaller cross sections. In other words, long and skinny foam pieces aremore difficult to manufacture with drilling, punching, or choppingtechniques especially where it is desired to provide a controlled oruniform cross sectional shape along the length thereof. For example,during chopping or punching, soft, foam material can collapse and/orbuckle which makes it more difficult to punch or chop long and skinnyelongate members with accuracy. Drilling or boring is also difficult assoft, foam material similarly collapses and can be more likely to twist,tear and/or fail when forming long and skinny elongate members.

By contrast, elongated members having sides that are alignable intocontinuous planes can be manufactured with greater ease, accuracy, andefficiency. For example, FIGS. 13D and 13E are schematic illustrationsof end views of stacked rectangular elongate members 110 r, andtriangular elongate members 110 t. As shown in these figures, the sidesof the elongate members 110 r, 110 p, when stacked, are alignable alongcontinuous flat planes P_(H), P_(V), P_(D). As such, cutting tools canbe passed through virgin block material along planar flat planarorientations to cut the elongate members 110 r, 100 t. The same would betrue for elongate members having other cross-sectional shapes, such asdiamond, square, and parallelogram (not illustrated).

FIG. 14 is a schematic illustration of a system for cutting machine 400for cutting a block 300 of virgin foam into elongate members. As shownin FIG. 14, cuts 310 h, 310 l, 310 v can be made to manufacture one ormore elongated members 110 r, for example, in some embodiments, inbatches 320. The batches 320 can be dimensioned so as to include asufficient number of the elongated members 110 for making one or afraction of one (½, ¼, etc.) individual comfort device 100. In someembodiments, the batches 320 comprise a single vertical cut 310V of theblock 300. In some embodiments, horizontal 310 h and 310 l cuts havebeen made prior to the vertical cut 310 v. Thus, at the end of makingthe vertical cur 310 v, the batch 320 is comprised of fully formedelongated members 110 r. Depending on the size of the elongated members110, the size of the batches 320 can vary. Bigger elongated members 110can require bigger batches 320. On the other hand, smaller elongatedmembers 110 can require smaller batches 320. Use of the batches 320during manufacturing process of the elongated members 110 can decreasemanufacturing time, increase efficiency, and improved control formanufacturing comfort devices 100. The manufacturing process of theelongated members 110 is further described below.

FIG. 14 is a schematic, perspective view of a type of commerciallyavailable foam block cutting machine 400 which can be used to cut foamfor making elongate members 110 disclosed herein. The machine 400 caninclude a conveyor belt system having an intake side conveyor 420 and anoutput side conveyor 422. The machine 400 also includes a horizontalcutter 410 h and a vertical cutter 410 v. The cutters 410 h, 410 v cancomprise different types of cutting devices including, but not limitedto, saw, tensioned blade saw, band saw, oscillating saw, hot wires, orlasers. The machine includes a programmable digital controller (notshown) that controls the vertical height and longitudinal position ofthe cutter 410 h, the lateral position of the vertical cutter 410 v, andthe movements of the input and output conveyors 420, 422, all of whichare independently controllable. Because this type of cutting device, iscommercially available, the details of its construction and operationare not provided herein.

In use, the block 300 is placed on the input conveyor belt 420 of themachine 400. In some embodiments, vertical position of the cutter 410 his disposed at a first position above the surface of the conveyors 420,422, the cutter 410 h is activated, and the conveyors 420, 422 move theblock 300 into the cutter 410 h so as to make a first horizontal cutthrough the bock 300 to create a first sheet 301 at the bottom of theblock 300. The height of the cutter 410 h can then be changed to asecond position and the process can be repeated to cut additional sheets302, 303, 304 until the block 300 is cut in to the desired number ofsheets. Each sheet 301, 302, 303, 304 can have a thickness correspondingof a dimension of the desired elongated member 110 r, such as a width123 b or depth 126 b (FIG. 6).

The machine 400 can also be used to split the block 300 intolongitudinal logs. For example, the machine 400 can adjust the positionof the vertical cutter 410 v to make the longitudinal cut 310 l, thendrive the conveyors 420, 422 to move the block 300 (or stacked sheets301, 302, 303, 304) against the vertical cuter 410 v so as to cut thesheets into left and right logs 306, 305.

After splitting the stacked sheets 301, 302, 303, 304 into left andright logs 306, 305, the machine can then move the vertical cutter 410 vacross the logs to make the vertical cut 310 v and therebysimultaneously make the final cut 310 v needed to fully form theelongated members 110 r and separate batches 320 of the elongatedmembers 110 r from the logs 306, 305. As each batch 320 is separatedfrom the logs 306, 305, the batched can fall over into a pile ofelongated members 110 r.

In some embodiments, the output conveyor 422 can be driven to first movea batch 320 away from the logs 306, 305, then bump the conveyor backtoward the logs 306, 305, to thereby induce the toppling of the batch320 away from the logs 306, 305 into a discrete pile of elongatedmembers 110 r. Additionally, the conveyor 422 can be driven to move abatch 320 of elongated members 110 r away from the logs 306, 305 beforethe next batch 320 of elongated members 110 r is cut from the logs 306,305.

Optionally, the conveyor 422 can be driven to move one batch 320sufficiently far from the logs 306, 305 such that when a subsequentbatch 320 is cut from the logs 306, 305, it falls in a manner such thatit remains spaced from the previous batch 320, for example, by apredetermined minimum spacing 424. The spacing 424 can be any desiredsize. In some embodiments, the size of the spacing 424 can be at leastabout ½ inch, the width of a human hand, a length providing clearancefor a pusher device (described below) or any other size. As such, thebatches 320 are cut from the logs 306, 305 and maintained in a spacedrelationship from each other. This can provide an additional optionalbenefit in that it is easier to pick up or sweep one more discretebatches 320 off of the conveyor 422 and into a cover 160 formanufacturing a comfort device 100 with improved efficiency.

The machine 400 can also include one or more pusher devices 430. Thepushers 430 can be configured to push batches 320 of the elongatedmembers 110 off of the conveyor 422. For example, in some embodiments,the pushers 430 can be configured to push the batches 320 towardsstaging/packing areas for comfort devices 100 in which batches 320 areinserted into a cover 160 of a comfort device 100 by a human or anothermachine (not illustrated).

As noted above, in some embodiments, each batch 320 can include a numberof elongated members 110 sufficient to fill a single comfort device 100.Optionally, the batches are sized such that a whole number (e.g., 1, 2,3, 4 . . . ) of batches 320 are sufficient for completely filling asingle comfort device 100. For example, each batch 320 can include anumber of elongated members 110 such that a single batch 320 or a wholenumber of batches 320 is enough to fill a single beanbag. In anotherexample, each batch 320 can include a number of elongated members 110sufficient to fill a single pillow case. In some embodiments, a batch320 is made first and the elongate inserts 110 are cut from the batch.In other embodiments, cuts are made to the block first and each batchesare then separated from other batches.

Optionally, a block of cushion material 300 can include more than onematerial. For example, the layers 301, 302, 303, and 304 can be madefrom different material compositions, or the same or similar materialcompositions but with different dimensions and/or specifications, suchas different sizes, densities, weights, textures, load deflectionrating, or other characteristic or specification. Such differentmaterial compositions can include, for example, but without limitation,polyurethane foam, memory foam, gel foam, latex rubber foam, convolutedphone, evlon foam, reflex foam, high density foam, high resiliencephone, Supreem™ foam, rebond foam, closed cell foam, or dry fast foam orother foams or cushion materials. As used here, the phrase “differentmaterial” is intended to mean either a) different compositions, asmemory foam is different from latex, and b) different materialcharacteristics, such as different dimensions (thickness, depth),different densities, different weights, etc. [are there other differentcharacteristics of cushion materials, measure of elasticity perhaps?]The layers 301, 302, 303, 304 are described below as being orientedhorizontally, stacked atop one another. However, the description belowapplies equally to layers 301, 302, 303, 304 being oriented vertically,side-by-side, such as the logs 305, 306.

In some embodiments, the desired different materials can be obtained insheet form or block form and cut into sheets, for example, using amachine such as the machine 400 (FIG. 14). Such sheets can then bestacked, such as in the configuration of the stacked sheets of layers301, 302, 303, 304 in FIG. 14. Alternatively, a block 300 can compriseside-by-side layers, such as logs 305, 306 made from differentmaterials.

With reference to FIGS. 15-18, the block 300 can comprise differentmaterials in various different orientations and arrangements. FIG. 15illustrates the block 300 comprise the of group of layers 301G, 302G.The first group of layers 301G includes layers 301 a, 301 b, 301 c, 301d. The second group of layers 302G includes layers 302 a, 302 b, 302 c,302 d. In the configuration illustrated in FIG. 15, the groups 301G,302G are stacked vertically, but in optional embodiments, the layers canbe arranged side-by-side.

In the variation shown in FIG. 16, the layers of the first material 301a, 301 b, 301 c, 301 d are interleaved with the layers of the secondmaterial 302 a, 302 b, 302 c, 302 d. As such, they are stacked, startingfrom the bottom, in the following order: 301 a, 302 a, 301 b, 302 b, 301c, 302 c, 301 d, 302 d. In this configuration, when the block 300 is cutalong a vertical cut 310 V, the individual elongate members 301 therewhich are thereby formed, would be in a group of mixed materials.Further, stacked in the configuration of FIG. 16, the elongate members301 are at least partially premixed, for example, the elongate members301 are more randomly mixed then groups of the elongate members 301 cutfrom the block illustrated in FIG. 15.

FIG. 17 illustrates a block 300 having four different materials, forminga plurality of each of layers 301, 302, 303, and 304. More specifically,in the configuration of FIG. 17, the layers are stacked in four groupsof different materials, 301G, 302G, 303G, 304G. Group 301G comprises tolayers of a first material 301 a, 301 b. Group 302G comprises twoadjacent layers of the second material 302 a, 302 b. The group 303Gcomprises two adjacent layers of a third material 303 a, 303 b. Thegroup 304G comprises two adjacent layers of a fourth material 304 a, 304b.

FIG. 18 illustrates a configuration in which the layers 301 ab, 302 ab,303 ab, and 304 ab are interleaved with each other, thereby providing amanner for pre-mixing the elongated members 301.

In the schematic illustration of the embodiment of FIG. 19, which is amodification of the embodiment of FIG. 14, the block of material 300includes a first group of layers of material 301G having five layers 301a-301 e, and the second group of layers 302G includes five layers 302a-302 e.

In operation, similarly to that described above with reference to FIG.14, as a batch 320 m comprised of elongated members 110 r made fromdifferent materials, is cut from the block 300, it falls over intotumbled batches 320 m onto the conveyor 422. By including differentmaterials in multiple layers in the block 300, the tumbled batches 320 mare partially pre-mixed. Optionally, in some embodiments, the batches320 m can be moved from the conveyor 422 into a mixer 500, which can bein the form of any of a variety of widely commercially available drummixers.

The drum mixer 500 can be configured to spin and tumble one or morebatches 320 m. In some embodiments, the mixer 500 is sized to receive,mix, and discharge one or a number of batches 320 m sufficient to fill asingle cushion cover 160.

After mixing the one or more batches 320 m, the batches 320 m can bedischarged to a cushion cover 160. In some embodiments, the mixer 500 ismounted for dumping into a funnel 502 leading to a cushion cover 160.Further, in some embodiments, mixer 500 can have a door on a lowerportion thereof, allowing mixed batches 320 m to be discharged bygravity into a cushion cover 160 disposed below.

In some embodiments, additional filler materials can be inserted intothe cover 160 and/or into the mixer 500 for later insertion into a cover160. For example, but without limitation, materials such as downfeathers, loose fiber, ball fiber, wool, shredded foam, shredded latex,or any mix of the above (schematically illustrated and identified byreference numeral 111 in FIG. 19). In some embodiments, the total weightof the additional filler material 111 can be about 5% or more of thetotal weight of all of the elongated inserts and filler materialinserted into the cover 160.

FIG. 20 is a flow chart illustrating a process 500 that can be used formanufacturing any of the elongated members 110, 110 a, 110 b, 110 c, 110d, 110 e or any other elongated members disclosed above. At blockoperation 502, the block of foam 300 is placed on the machine 400. Asdiscussed above, various types of foams may be used for the purpose ofthe present disclosure.

At operation block 504, the block 300 is cut. Various types of cuts 310can be made to the block 300. In some embodiments, the cuts 310 h havingcutting planes parallel to the x-y axis are made. In some embodiments,the cuts 310 v having cutting planes parallel to the x-z axis are made.In some embodiments, the cuts 310 l having cutting planes parallel tothe y-z axis are made. In some embodiments, the cuts 310 have cuttingplanes that are linear. In other embodiments one or more of the cuts 310have nonlinear cutting planes. The cuts 310 can be made to manufacturethe elongated members 110 having different sizes. The cuts 310 can alsobe made to manufacture the elongated members 110 having differentcross-sections. The cuts 310 can be configured to generate a pile ofinserts comprising sufficient number of inserts to fill a single comfortdevice. In some embodiments, each pile of inserts is an individual batch320 for a single comfort device.

The cuts 310 can be horizontal cuts. In some embodiments, the cuts 310 vare vertical cuts. The cuts 310 can be made vertical to surfaces of theblock 300 such that the cuts 310 are transverse to the surfaces. In someembodiments, the cuts 310 are made at an angle with respect to thesurfaces of the block 300. The machine 400 can make a series ofhorizontal cuts 310 h and one or more longitudinal cuts 310 l togenerate one or more columns from the block 300. For example, horizontalcuts 310 h can be made to define heights of the elongated members 110and longitudinal cuts 310 l can be made to define length of theelongated members 110. Another set of vertical cuts 310 v can be made todefine depths of the elongated members 110.

At block 506, after the cuts 310 are made, the elongated members 110 canbe collected. The process of collecting the elongated members 110 can bemanual or automatic. In some embodiments, a number of elongated members110 can be collected sufficient to fill up individual comfort device100.

At block 508, the inserts 110 cut from the block 300 can be organizedinto separate piles or batches 320. For example, the machine 400 can beconfigured to output batches 320 of elongated members 110 that comprisea sufficient number of elongated members 110 such that one or a wholenumber of batches are sufficient to completely fill one comfort device100. In some embodiments, the organization of elongated members 110 isachieved by controlling the conveyor 422 to accumulate and space apartbatches.

In some embodiments, the pusher 430, shown in FIG. 14, is controlled tomove elongated members 110 so as to form batches 320. In someembodiments, the pusher 430 can be controlled to push one or more pilesof elongated members 110 to different positions on the output conveyor422 or to different downstream conveyor belts (not shown). The machine400 can be configured to use the pusher 430 to push certain piles ofinserts 110 or batches 320 to one direction and moving other piles ofinserts 110 or batches 320 to a different direction. Optionally, thepiles can be separated by a predetermined distance 424, allowing thepusher 430 to readily transfer the piles to different output conveyorbelts. Separating the piles (or batches 320) from the block 300 by thepredetermined distance 424 can also allow the next batch 320 to be cutwithout any interference and/or comingling. In some embodiments, thepredetermined distance 424 is about 1 or more inches. This predetermineddistance 424 between the piles can be adjusted.

At block 510, the elongated members 110 can be placed into thecompartment 168 within the cover 160 of the comfort device 100. In someembodiments, the elongated members 110 are inserted into the compartment168 defined by the cover 160 of the comfort device 100. In someembodiments, different types of the elongated members 110 (e.g., size,density, shape, and/or material) are placed in different compartments168 to provide unique elastic properties and/or compressive responses.

FIG. 21 illustrates a method 530 for manufacturing one or more elongatedmembers 110 from a block of foam material 300. At operation block 532,the block 300 is placed on a conveyor belt of a cutting machine. Theblock 300 can be made of foam. Various different kinds of foam can beused for the purpose of the present disclosure including, but notlimited to, polyurethane foam, memory foam, gel foam, latex rubber foam,convoluted phone, evlon foam, reflex foam, high density foam, highresilience phone, Supreem foam, rebond foam, closed cell foam, or dryfast foam.

At block 534, horizontal cuts 310 h along cutting planes parallel to thex-y axes are made. For example, the horizontal cutter 410 h can be usedto cut the block into a plurality of sheets of foam by driving theconveyors 420, 422 so as to pass the block 300 against the cutter 410 hin movements parallel to the x-y plane.

At block 536, one or more longitudinal cuts 310 l having cutting planesparallel to z-y axis can be made. For example, the vertical cutter 410 vcan be used to cut the block 300, which has already been cut into aplurality of sheets, into a plurality of logs of foam by driving theconveyors 420, 422 so as to pass the block 300 against the cutter 410 vin movements parallel to the z-y plane.

At block 538, vertical cuts 310 v having cutting planes parallel to x-zaxis are made. For example, the vertical cutter 410 v can be used to cutthe block 300, which has already been cut into a plurality of sheets andlogs of foam, by driving the cutter 410 v laterally through the block300 in movements parallel to the x-z plane. In some embodiments, onlyone cut 310 v with cutting plane parallel to the x-z axis is made toform a single batch 320 of elongated members 110. In other embodiments,a plurality of vertical cuts 310 v with cutting planes parallel to thex-z axis are made for each batch of elongated members 320.

In some embodiments, the longitudinal cuts 310 l with cutting planesparallel to the y-z axis can be equidistant from each other. Forexample, a first cut is made 8 inches away from a first side of theblock 300, while a second cut is made 8 inches away from the first cut,where the second cut is further away from the first side of the block300 and the first cut. In this example the first cut and the second cutcan define the 8 inch length of the elongated members 110. In anotherexample, a fourth cut and a fifth cut is made one inch and 2 inches awayfrom a second side of the block 300. In this example the third cut andthe fourth cut can define the one inch width or 1 inch height of theelongated members 110. In other embodiments, the cuts 310 are notequidistant from each other.

At block 540, the elongated members 110 manufactured by the cuts 310described above are collected to be put into individual comfort devices100.

In some embodiments, the method 530 is used for manufacturing batches ofelongate elongated members 110 from a block 300 of foam material. Themethod 530 can comprise placing the block 300 of foam material onto aninput conveyor belt of a cutting machine, where the input conveyor beltof the cutting machine defines an input axis. The method 530 can furthercomprise transferring the block 300 of foam material along the inputconveyor belt to a cutting area of the cutting machine. The method 530can further comprise cutting the block 300 into a plurality ofhorizontal layers and at least two columns and generating a first batchfrom the large block of foam material by making at least a first cut tothe horizontal layers. The first cut can be transversal with respect tothe horizontal layers of the block 300. The method 530 can furthercomprise separating the first batch from a first remainder of the largeblock of foam material and generating a second batch from the firstremainder of the large block of foam material by making at least asecond cut to the horizontal layers, the second cut being transversalwith respect to the horizontal layers. The second batch, just like thefirst batch, can be separated from a second remainder of the block 300of foam material.

The method 530 of manufacturing batches of elongate elongated members110 from a block 300 of foam material can comprise placing the block 300of foam material onto an input conveyor belt of a cutting machine. Theinput conveyor belt can define an input axis while the block 300 of foammaterial can have a width, a height, and a depth. The method 530 canfurther comprise moving the block 300 of foam material in a firstdirection along the input conveyor belt, the first direction beingparallel to the input axis. The method 530 can also comprise performingone or more first cuts, performing one or more second cuts, andperforming a first of one or more third cuts, where the first of one ormore third cut generates a first batch of elongate inserts. The firstbatch of elongate inserts can be separated from a first remainder of thelarge block of foam material. The method 530 can further compriseperforming a second of one or more third cuts to generate a second batchof elongate inserts, where the second batch can be separated from asecond remainder of the large block of foam material.

In other embodiments, the one or more first cuts are parallel to a firstplane defined by the depth and the width of the large block of foammaterial. In some embodiments, the one or more second cuts are parallelto a second plane defined by the depth and the height of the large blockof foam material, while the one or more third cuts are parallel to athird plant defined by the width and the height of the large block offoam material. The one or more second cuts and the one or more thirdcuts can be orthogonal to the one or more first cuts.

In some embodiments, a method for efficient, batch manufacturing ofpillows filled with a plurality of elongate inserts can be performed bya cutting machine cutting a large block of foam material, cut in batchesas described above. The method can include a combination of thefollowing steps: (1) placing the block of foam material onto an inputconveyor belt of the cutting machine, the input conveyor belt definingan input axis; (2) transferring the large block of foam material alongthe input conveyor belt to a cutting area of the cutting machine; (3)cutting the large block of foam material into a plurality of horizontallayers; (4) generating a first batch from the large block of foammaterial by making at least a first cut to the horizontal layers, thefirst vertical cut being transverse with respect to the horizontallayers; (5) transferring the first batch to a first output conveyorbelt; (6) collecting a first plurality of elongate inserts from thefirst batch; (7) inserting the first plurality of elongate inserts intoa first pillow; (8) generating a second batch from the large block offoam material by making at least a second vertical cut to the horizontallayers, the second vertical cut being transverse with respect to thehorizontal layers; (9) transferring the second batch to a second outputconveyor belt; (10) collecting a second plurality of elongate insertsfrom the second batch; and (11) inserting the second plurality ofelongate inserts into a second pillow.

In some embodiments, the method for efficient, batch manufacturing ofpillows can further include one or more of the following features in anycombination: (i) wherein a plurality of horizontal layers have the sameheight; (ii) wherein the first output conveyor belt and the secondoutput conveyor belt define a first output axis and a second outputaxis, respectively; (iii) wherein the first output axis and the secondoutput axis are different from the input axis and different from eachother; (iv) wherein the first batch and the second batch comprise anumber of elongate inserts sufficient to fill at least a predeterminedportion of the first pillow and the second pillow, respectively; (v)wherein the predetermined portion is at least 75% of the first pillowand the second pillow; (vi) wherein the location and the number of thefirst cut are associated with the size and/or volume of the firstpillow; (vii) wherein the location and the number of the second cut areassociated with the size and/or volume of the second pillow; (viii)wherein a volume of the first batch and a volume of the second batch arethe same; and (ix) wherein a volume of the first batch and a volume ofthe second batch are different.

In other embodiments, the method for efficient, batch manufacturing ofpillows can further include transferring the first batch to a firstconveyor belt further comprising: (i) moving the first batch and aremainder of the large block of foam material along the input conveyorbelt; (ii) transferring the first batch to the first output conveyorbelt while the remainder of the large block of foam material remains onthe input conveyor belt; and (iii) moving the first batch in a firstdirection along the first output conveyor belt.

In other embodiments, the method for efficient, batch manufacturing ofpillows can further include transferring the second batch to a secondconveyor belt further comprising: (i) moving the first batch and aremainder of the large block of foam material along the input conveyorbelt; (ii) transferring the first batch to the second output conveyorbelt while the remainder of the large block of foam material remains onthe input conveyor belt; and (iii) moving the first batch in a seconddirection along the second output conveyor belt.

In some embodiments, a method for manufacturing batches of elongateinserts from a large block of foam material can include a combination ofthe following steps: (1) placing the large block of foam material ontoan input conveyor belt of a cutting machine, the input conveyor beltdefining an input axis; (2) transferring the large block of foammaterial along the input conveyor belt to a cutting area of the cuttingmachine; (3) cutting the large block of foam material into a pluralityof horizontal layers and at least two columns; (4) generating a firstbatch from the large block of foam material by making at least a firstcut to the horizontal layers, the first cut being transversal withrespect to the horizontal layers; (5) separating the first batch from afirst remainder of the large block of foam material; (6) generating asecond batch from the first remainder of the large block of foammaterial by making at least a second cut to the horizontal layers, thesecond cut being transversal with respect to the horizontal layers; and(7) separating the second batch from a second remainder of the largeblock of foam material.

In some embodiments, a method of manufacturing batches of elongateinserts from a large block of foam material can include a combination ofthe following steps: (1) placing the large block of foam material ontoan input conveyor belt of a cutting machine, the input conveyor beltdefining an input axis, the large block of foam material having a width,a height, and a depth; (2) moving the large block of foam material in afirst direction along the input conveyor belt, the first direction beingparallel to the input axis; (3) performing one or more first cuts; (4)performing one or more second cuts; (50 perform a first of one or morethird cuts, the first of one or more third cut generating a first batchof elongate inserts; (6) separating the first batch of elongate insertsfrom a first remainder of the large block of foam material; (7)performing a second of one or more third cuts, the second of one or morethird cut generating a second batch of elongate inserts; and (8)separating the second batch of elongate inserts from a second remainderof the large block of foam material.

In other embodiments, the above method can further include one or moreof the following features in any combination: (i) the one or more firstcuts being parallel to a first plane defined by the depth and the widthof the large block of foam material; (ii) the one or more second cutsbeing parallel to a second plane defined by the depth and the height ofthe large block of foam material; (iii) the one or more third cuts beingparallel to a third plane defined by the width and the height of thelarge block of foam material; and (iv) wherein the one or more secondcuts and the one or more third cuts are orthogonal to the one or morefirst cuts.

During regular use of the comfort device 100, the elongated members 110can move in various ways. The elongated members 110 can move verticallyor horizontally during normal use (e.g., comfort device supporting auser's head). In addition, the elongated members 110 can also be twistedand bent. In order for the elongated members 110 to withstand repeated,prolonged uses of the comfort device 100, the elongated members 110, insome embodiments, have certain material properties, compressiveresponses, and/or elastic properties. Such properties allow theelongated member 110 to withstand the shearing stress, bending moments,and/or torques resulting from repeated, prolonged uses of the comfortdevice 100, and to retain its initial size, volume, and/or shape. Insome embodiments, the dimensions (e.g., length, width, height, and/orcross-sectional area) of the elongated member 110 affect the compressiveresponses and/or elastic properties. Therefore, varying the dimensionsof the elongated member 110 can change the compressive responses and/orelastic properties of the elongated member 110.

Various other modifications, adaptations, and alternative designs are ofcourse possible in light of the above teachings. Therefore, it should beunderstood at this time that within the scope of the appended claims theinvention may be practiced otherwise than as specifically describedherein. It is contemplated that various combinations or subcombinationsof the specific features and aspects of the embodiments disclosed abovemay be made and still fall within one or more of the inventions.Further, the disclosure herein of any particular feature, aspect,method, property, characteristic, quality, attribute, element, or thelike in connection with an embodiment can be used in all otherembodiments set forth herein. Accordingly, it should be understood thatvarious features and aspects of the disclosed embodiments can becombined with or substituted for one another in order to form varyingmodes of the disclosed inventions. Thus, it is intended that the scopeof the present inventions herein disclosed should not be limited by theparticular disclosed embodiments described above.

Moreover, while the invention is susceptible to various modifications,and alternative forms, specific examples thereof have been shown in thedrawings and are herein described in detail. It should be understood,however, that the invention is not to be limited to the particular formsor methods disclosed, but to the contrary, the invention is to cover allmodifications, equivalents, and alternatives falling within the spiritand scope of the various embodiments described and the appended claims.Any methods disclosed herein need not be performed in the order recited.The methods disclosed herein include certain actions taken by apractitioner; however, they can also include any third-party instructionof those actions, either expressly or by implication. For example,actions such as “placing the inserts within the compartment” includes“instructing the placing the inserts within the compartment.”

The ranges disclosed herein also encompass any and all overlap,sub-ranges, and combinations thereof. Language such as “up to,” “atleast,” “greater than,” “less than,” “between,” and the like includesthe number recited. Numbers preceded by a term such as “approximately”,“about”, and “substantially” as used herein include the recited numbers(e.g., about 10%=10%), and also represent an amount close to the statedamount that still performs a desired function or achieves a desiredresult. For example, the terms “approximately”, “about”, and“substantially” may refer to an amount that is within less than 10% of,within less than 5% of, within less than 1% of, within less than 0.1%of, and within less than 0.01% of the stated amount.

Personal support devices, such as pillows or larger devices such as softfurniture in the shape of chairs tor love seats, sometimes referred toas “bean bag” furniture, provide support and comfort for users bysupporting structures of different bodily parts such as head, neck,shoulders, hip, and spine. They can also help in preventing andalleviating different types of back and neck pain, as well as shoulder,hip, and other forms of joint pain. Pillows, for example, can providesupport for the head, neck, and shoulders by evenly distributinggravitational forces during sleep.

Some personal cushion devices can be in the form of an outer shellfilled with pieces of resilient material. The material properties of theinserts provide the desired support and comfort. Different types ofinserts can provide different levels of support and comfort. Differentinserts have different compressive responses and/or elastic properties,which results in different levels of support and comfort for users.Inserts incorporating harder materials can have less “give” then insertsincorporating softer materials.

In addition, different levels of support and comfort can be provided byvarying characteristics of the manner and/or extent to which a cushionis filled, for example, by varying a total weight and/or volume of theelongate inserts. The total weight and total volume of the elongateinserts can be used to calculate “weight ratio” and “volumetric ratio”of the elongate inserts. The “weight ratio”, as used herein, canindicate a ratio between the weight of the elongate inserts and theweight of the pillow with the elongate inserts. The “volumetric ratio”,as used herein, can indicate a ratio between the volume occupied by theelongate inserts in a relaxed state and the volume occupied by thepillow with the elongate inserts inside. Discuss with Sean

Different weight and/or volumetric ratios between the pillow inserts andthe pillows can result in different amount of air space between theinserts within the pillow. Increase in weight and/or volumetric ratiobetween the inserts and the pillows can be achieved by an increase inthe number of the inserts in the pillows. Increase in the number of theinserts can result in an increase in volume occupied by the inserts andthus less volume occupied by air within the pillow. However, it is alsopossible that decrease in weight and/or volumetric ratio between theinserts and the pillows may not necessarily result in decrease in thenumber of the inserts in the pillows.

Increase in volumetric ratio can provide increased compression responseand therefore increased support for the users during use. In someembodiments, increase in weight ratio can also provide increasedcompression response and therefore increased support for the usersduring use. Compression response and/or elastic properties of the pillowinserts can also be modified by varying the shapes of pillow inserts.For example, flat rectangular cuboid foam inserts can have differentcompression response and/or elastic properties than elongatedcylindrical foam inserts.

What is claimed is:
 1. A bedding pillow comprising: an outer covercomprising an upper sidewall and a lower sidewall; a first internalcompartment disposed within the cover between the upper sidewall and thelower sidewall; an opening disposed in the outer cover, opening into theinternal compartment of the outer cover; a fastening assembly disposedat the opening comprising at least a first fastening element, thefastening element being moveable between opened and closed positions;and a plurality of elongated inserts disposed in the first compartmentof the outer cover, the plurality of elongated inserts comprising anopen cell foam material, a first end, a second end, an intermediateportion, and a length between the first end and the second end, theplurality of elongated inserts having a cross-section defining across-sectional area between about one-sixteenth of a square inch andabout one-half of a square inch, the cross-section also comprising atleast a plurality of cross-sectional dimensions, wherein the length isat least 15 times the size of a greatest one of the cross sectionaldimensions, and wherein the length of the plurality of elongate insertsis greater than 5 inches; and wherein the plurality of elongate insertsare shaped and sized in such a way that during use of the bedding pillowat least some of the elongate inserts are compressed and loaded intension while the remaining elongate inserts are uncompressed, thuscreating a trampoline-like effect.
 2. The bedding pillow of claim 1,wherein the plurality of elongate inserts have a length of at least 8inches.
 3. The bedding pillow of claim 1, wherein the cross-section ofthe plurality of elongated inserts extend perpendicular to the length ofthe plurality of elongated inserts.
 4. The bedding pillow of claim 1,wherein the first end of the plurality of elongate inserts has a firstcross-section, wherein the second end of the plurality of elongateinserts has a second cross-section, wherein the intermediate portion hasa third cross-section, wherein the first cross-section and the secondcross-section have the same cross-sectional shape, and wherein the thirdcross-section has a different cross-sectional shape than that of thefirst and the second cross-section.
 5. The bedding pillow of claim 1additionally comprising loose filler material mixed with the pluralityof elongated inserts disposed in the first compartment, wherein theloose filler material is at least 5% of the total weight of all of theloose filler material and elongated inserts in the first compartment. 6.The bedding pillow of claim 5, wherein the loose filler material is atleast one of down feathers, loose fiber, ball fiber, wool, shreddedfoam, and shredded latex.
 7. A bedding pillow comprising: an outer covercomprising a compartment disposed within the outer cover; an openingdisposed in the outer cover, opening into the compartment of the outercover; a fastening assembly disposed at the opening comprising afastening element being moveable between opened and closed positions;and a plurality of elongated inserts disposed in the first compartmentof the outer cover, the plurality of elongated inserts comprising afirst end, a second end, an intermediate portion, and a length betweenthe first end and the second end, the plurality of elongated insertshaving a cross section comprising at least a plurality ofcross-sectional dimensions, and wherein the length is at least eighttimes a greatest one of the cross sectional dimensions; and wherein theplurality of elongate inserts are shaped and sized in such a way thatduring use of the bedding pillow at least some of the elongate insertsare compressed and loaded in tension while the remaining elongateinserts are uncompressed, thus creating a trampoline-like effect.
 8. Thebedding pillow of claim 7, wherein the plurality of elongated insertsfurther comprise an open cell foam material.
 9. The bedding pillow ofclaim 7, wherein the plurality of elongate inserts have a length of atleast 8 inches.
 10. The bedding pillow of claim 7, wherein thecross-section of the plurality of elongated inserts extend perpendicularto the length of the plurality of elongated inserts.
 11. The beddingpillow of claim 7, wherein the cross-section of the plurality ofelongated inserts define a cross-sectional area of at leastone-sixteenth of a square inch.
 12. The bedding pillow of claim 7additionally comprising loose filler material mixed with the pluralityof elongated inserts disposed in the first compartment, wherein theloose filler material is at least 5% of the total weight of all of theloose filler material and elongated inserts in the first compartment.13. The bedding pillow of claim 12, wherein the loose filler material isat least one of down feathers, loose fiber, ball fiber, wool, shreddedfoam, and shredded latex.
 14. A bedding pillow comprising: an outercover; an internal compartment disposed within the cover; and aplurality of elongated Inserts disposed in the internal compartment ofthe outer cover, the plurality of elongated inserts comprising a firstend and a second end, and a length between the first end and the secondend, the plurality of elongate inserts having a length larger than about6 inches; and wherein the plurality of elongate inserts are shaped andsized in such a way that during use of the bedding pillow at least someof the elongate inserts are compressed and loaded in tension while theremaining elongate inserts are uncompressed, thus creating atrampoline-like effect.
 15. The bedding pillow of claim 14, wherein theplurality of elongated inserts have a cross-section extendingperpendicular to the length of the plurality of elongated inserts, thecross-section defining a cross-sectional area of at least one-sixteenthof a square inch and less than about ¾ of a square inch.
 16. The beddingpillow of claim 14, wherein the first end of the plurality of elongateinserts has a first cross-section, wherein the second end of theplurality of elongate inserts has a second cross-section, wherein theintermediate portion has a third cross-section, and wherein the firstcross-section, the second cross-section, and the third cross-section hasthe same shape and size.
 17. The bedding pillow of claim 14, wherein thefirst end of the plurality of elongate inserts has a firstcross-section, wherein the second end of the plurality of elongateinserts has a second cross-section, wherein the intermediate portion hasa third cross-section, wherein the first cross-section and the secondcross-section have the same cross-sectional shape, and wherein the thirdcross-section has a different cross-sectional shape than that of thefirst and the second cross-section.
 18. The bedding pillow of claim 14,wherein the plurality of elongate inserts have varying lengths.
 19. Thebedding pillow of claim 14 additionally comprising loose filler materialmixed with the plurality of elongated inserts disposed in the internalcompartment, wherein the loose filler material is at least 5% of thetotal weight of all of the loose filler material and elongated insertsin the internal compartment.
 20. The bedding pillow of claim 19, whereinthe loose filler material is at least one of down feathers, loose fiber,ball fiber, wool, shredded foam, and shredded latex.